Splicing apparatus and method

ABSTRACT

An apparatus and method for splicing tapes dispensed from a tape dispenser. According to one embodiment, a first, running or unwinding roll of tape is provided with a first splicing element secured to its trailing end portion. A second, stationary or standby roll of tape is provided with a second splicing element secured to its leading end portion. The second splicing element comprises a body made of a self-supporting material and formed with at least one aperture sized to receive the tape from the first roll. While tape is being dispensed from the first roll, the running tape is inserted into the aperture of the second splicing element. When the first roll of tape becomes depleted, the first splicing element engages the second splicing element, thereby splicing the leading end portion of the second tape roll to the trailing end portion of the first tape roll.

FIELD

The present disclosure concerns an apparatus and method forautomatically splicing an unwinding roll of material to a stationaryroll of material, such as tape.

BACKGROUND

Modem consumer and industrial packaging often includes reinforcing tapesor tear tapes as part of their construction. Various tape dispensershave been designed to dispense such tapes into corrugator and packagingequipment. Known tape dispensers include a first spindle that supportsan unwinding spool of tape and a second spindle that supports astationary, or standby, spool of tape. To provide a continuous feed oftape, splicing techniques have been developed for automatically splicingtogether the trailing end of the unwinding spool of tape to the leadingend of the standby spool of tape.

One example of a tape dispenser and splicing technique is disclosed inU.S. Pat. No. 4,917,327 to Asbury, Jr. et al. In the splicing techniquedisclosed in the '327 patent, the trailing end of a first spool of tapeis provided with a pin and the leading end of a second spool of tape isprovided with a piece of string or cord. As the first spool of 20 tapeis being dispensed, an operator forms a loop around the tape of thefirst spool with the string by placing the string around the tape andtying the ends of the string together. When the first spool is depleted,the pin engages the loop to link the tape of the first spool to the tapeof the second spool, causing the tape of the first spool to cause thesecond spool to begin rotating and pull the tape from the second spoolinto the packaging equipment.

A continuing need exists for improved techniques for splicing one spoolof tape to another spool of tape.

SUMMARY

The present disclosure concerns embodiments of an apparatus and methodfor splicing tapes dispensed from a tape dispensing machine where acontinuous supply of tape is required. According to one embodiment, afirst, running or unwinding roll of tape is provided with a firstsplicing element secured to its trailing end portion. A second,stationary or standby roll of tape is provided with a second splicingelement secured to its leading end portion. The second splicing elementcomprises a body made of a self-supporting material and formed with atleast one aperture sized to receive the tape from the first roll.

When the rolls are installed on a tape dispenser and the first roll isrunning, an operator brings the second splicing element, which issecured to the leading end portion of the second, standby tape roll, inclose proximity to the running tape and inserts the running tape intothe aperture in the second splicing element. The aperture is sized toallow the running tape, but not the first splicing element, to freelypass through the aperture. Thus, when the first roll of tape becomesdepleted, the first splicing element engages the second splicingelement, thereby splicing the leading end portion of the second taperoll to the trailing end portion of the first tape roll.

The spicing system disclosed in the present application provides severaladvantages over the “pin and loop” splicing system disclosed in the '327patent. For example, less operator involvement and dexterity is requiredbecause the second splicing element can be easily placed around therunning tape without the need to tie a knot with a string. In addition,in the prior system, the splice can depend on the quality of the knotand/or the size of the loop formed around the running tape. If the knotis too loose or if the loop is too large, the pin can pass through thetied string, resulting in the failure of the splice. If the knot is tootight or if the loop is too small, the running tape may contact theedges of the running tape and the friction can cut the string, resultingin the failure of the splice. In addition, a loop that is made too smallcan cause the running tape to prematurely pull the standby tape beforethe first tape roll is depleted, resulting in the first and second tapesbeing dispensed together into the packaging equipment. The splicingsystem disclosed herein does not suffer from such limitations and can beused to achieve splices at dispensing rates not previously possible withthe pin and loop system. In certain embodiments, for example, thesplicing elements disclosed herein can be used to form splices atdispensing rates of at least about 1100 feet per minute, and moredesirably about 1400 feet per minute and greater.

In some package-forming applications, it may be desirable to provide forconsistent spacing between the spliced ends of tapes from one splice tothe next. For example, in one such application, multiple radio frequencyidentification (RFID) devices, used for managing and tracking packages,are attached to reinforcing tape at equally spaced locations on apackage, as further described in co-pending U.S. application Ser. No.11/122,977, filed May 4, 2005, which is incorporated herein byreference. Providing constant spacing (or no spacing) between thespliced ends of tapes facilitates the proper placement of the RFIDdevices on the tapes. Unfortunately, in the prior pin and loop splicingsystem, the spacing between the adjacent ends of the spliced tapes canvary depending on the size of the loop that is formed. However, in thesplicing system disclosed herein, the second splicing element has anaperture of a predetermined size and therefore can achieve consistentspacing between the spliced ends of tapes in successive splices.

In particular embodiments, the second splicing element includes a slitextending from the aperture to an outer peripheral edge of the body anda flexible peripheral portion at least partially bounding the aperture.To insert the running tape into the aperture, an operator bends theperipheral portion to create a gap between the opposing edges of theslit and inserts the running tape into the aperture via the gap.

In another embodiment, the second splicing element is formed with apermanent opening or gap extending from the aperture to an outerperipheral edge of the body. The gap is of sufficient width to allow anoperator to insert the running tape through the gap and into theaperture without bending or flexing of the peripheral portion of thebody surrounding the aperture.

The second splicing element can be secured to the standby tape roll byinserting the leading end portion of the tape through the aperture andfolding back and securing the tape to itself so as to form a loopextending through the aperture. Alternatively, the second splicingelement can be formed with two separate apertures, one of which is usedto secure the leading end portion of the standby tape roll and the otherof which receives the running tape.

In another embodiment, the second splicing element includes a first bodyportion and a second body portion foldably coupled to each other along afolding axis, allowing the first and second body portions to be foldedclosed and opened relative to each other. The first body portionincludes a first aperture for receiving the running tape, a slitextending from the first aperture to an outer peripheral edge of thefirst body portion, and a flexible tab portion at least partiallybounding the first aperture. The second body portion includes a secondaperture for receiving the running tape, a slit extending from the firstaperture to an outer peripheral edge of the first body portion, and aflexible tab portion at least partially bounding the first aperture. Inuse, an operator first places the first body portion around the runningtape by bending the respective tab portion to create a gap and insertingthe running tape into the first aperture via the gap. The operator thenplaces second body portion around the running tape in a similar mannerand folds the body portions against each other. A suitable adhesive,such as a layer of double-sided tape or a liquid adhesive, can beprovided to adhesively secure the body portions together in the closedposition.

In still another embodiment, the first and second body portions arepivotally coupled to each other by a pivot pin extending through thebody portions, rather than being foldably coupled to each other. Thebody portions can be pivoted relative to each other in mutually parallelplanes between a closed and open position.

In yet another embodiment, the second splicing element comprises awire-like, elongated piece of material formed so as to have a closedgeometric shape having overlapping end portions. The splicing elementcan be placed around the running tape by moving the leg portions awayfrom each other and inserting the running tape through the openingbetween the leg portions.

The foregoing and other objects, features, and advantages of theinvention will become more apparent from the following detaileddescription, which proceeds with reference to the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic illustration of a tape dispenser that is operableto dispense tape from a first, running spool of tape, and then from asecond, standby spool of tape.

FIG. 1B is a schematic illustration of a tape dispenser, according toanother embodiment.

FIG. 2 is an illustration showing a splicing technique for automaticallysplicing the trailing end portion of a first, running tape to theleading end portion of a second tape of a stationary spool.

FIG. 3 is an illustration showing the splicing element affixed to thetrailing end portion of the running tape shown in FIG. 2.

FIG. 4 is a perspective view of the splicing element that is secured tothe leading end portion of the second, standby tape shown in FIG. 2.

FIG. 5 is a perspective view of the splicing element of FIG. 4 shownafter being secured to the leading end portion of the standby tape.

FIG. 6 is a perspective view of the splicing element of FIG. 4 shownafter the running tape is introduced into an aperture in a first bodyportion of the splicing element.

FIG. 7 is a perspective view of the splicing element of FIG. 4 shownafter the running tape is introduced into an aperture in a second bodyportion and the first and second body portions are folded closed.

FIG. 8 is a perspective view of a splicing element, according to anotherembodiment, adapted to be secured to the leading end portion of astandby tape, shown in an open position.

FIG. 9 is a perspective view of the splicing element of FIG. 8 shown ina closed position.

FIG. 10 is an illustration of a first splicing element secured to thetrailing end portion of a running tape and a second splicing elementsecured to the leading end portion of a standby tape, shown just priorto the first splicing element engaging the second splicing element toform a splice, according to another embodiment.

FIG. 11 is an illustration of a first splicing element secured to thetrailing end portion of a running tape and a second splicing elementsecured to the leading end portion of a standby tape, according toanother embodiment.

FIG. 12 is an illustration of the splicing elements of FIG. 11 showingthe second splicing element placed around the running tape and beingengaged by the first splicing element.

FIG. 13 is an illustration of a first splicing element secured to thetrailing end portion of a running tape and a second splicing elementsecured to the leading end portion of a standby tape, according toanother embodiment.

FIG. 14 is an illustration of the splicing elements of FIG. 13 showingthe second splicing element placed around the running tape and beingengaged by the first splicing element.

DETAILED DESCRIPTION

As used herein, the singular forms “a,” “an,” and “the” refer to one ormore than one, unless the context clearly dictates otherwise.

As used herein, the term “includes” means “comprises.”

The present disclosure concerns embodiments of a splicing technique,such as can be used to splice the trailing end of an unwinding roll oftape being dispensed to the leading end of a stationary or standby rollof tape. The splicing technique can be implemented in any tape dispenseroperable to dispense tape from a first, running spool of tape and then asecond, standby spool of tape.

FIG. 1A, for example, shows a schematic illustration of a dispensingapparatus, indicated generally at 10, for dispensing tape from a firstroll, or spool of tape 16 and a second roll, or spool of tape 18.Apparatus 10 includes a frame 11. Mounted on the frame 11 for rotationalmovement are a first spindle 12 and a second spindle 14. The firstspindle 12 supports the first spool of tape 16 and the second spindle 14supports the second spool of tape 18. Tape T from one of the first andsecond spools 16, 18 is routed over a fixed roller 20, down to atensioning roller 22 of a tension-control mechanism 24, and over a fixedroller 26, and then is fed to downstream equipment (e.g., corrugator orother packaging equipment used for producing, for example, foldingcartons), as indicated by arrow A. Apparatus 10 also can be used todispense tape into other types of tape-consuming devices, such asapplicators used to apply tape to wood substrates (e.g., plywood).

The tension-control mechanism 24 is movable in two directions (upwardlyand downwardly, as indicated by double-headed arrow B, in theillustrated embodiment) along an upright rail 25 to vary the path lengthof the tape in response to changes in tension in the tape. Thetension-control mechanism 24 is pulled downwardly by an elongatedbiasing member 28 (which can be a piece of elastic material, such assurgical tubing) and upwardly by the tension in the tape. Thus, whentape tension is high (i.e., when the current spool is providing tapeslower than is required by downstream equipment, such as at thebeginning of a spool), the tension-control mechanism moves upwardly. Theupward movement of the tension-control mechanism 24 shortens the tapepath so that tape can be fed to downstream equipment without requiringthe spool to dispense a corresponding length contemporaneously.Conversely, when tape tension is low (i.e., when the current spool isproviding tape faster than is required by downstream equipment), thebiasing member 28 causes the tension-control mechanism 24 to assume alower position (as shown in FIG. 1) to increase the length of the tapepath.

The biasing member 28 is reeved around a pulley 32 of a pivoted lever34, and has a first end 30 connected to the tension-control member 24and a second end 36 secured to an extension 54 of frame 11. Lever 34 ismounted for pivoting movement about a pivot pin 56, as indicated bydouble-headed arrow C.

A brake assembly 38 applies a controlled braking force to the first andsecond spindles 12, 14, respectively. The brake assembly 38 includes abrake band 40 that extends about portions of spindles 12, 14 and servesto retard their rotation. An upper end portion 42 of the band 40 isaffixed to frame, as at 42 a, and therefore is stationary. A lower endportion 44 of the band 40 is coupled to extension 54 of frame 11 by acoil spring 46. Spring 46 pulls upwardly on the lower end portion 44 ofband 40, causing the band to automatically apply a quiescent brakingforce to the spindles 12, 14. As used herein, the term “quiescentbraking force” refers to a braking force applied to a spindle when thespindle is at rest. Other brake assembly configurations can beimplemented in the dispensing apparatus.

As shown in FIG. 1A, the lower end portion 44 of band 40 is coupled to afirst end portion 48 of the lever 34 by a connecting member 50. Thebrake assembly 38, lever 34, tension-control mechanism 24, and biasingmember 28 cooperate to form a feedback mechanism, by which the brakeassembly 38 applies a controlled braking force in response to changes inthe tension in the tape. More specifically, when tape tension is high,the tension-control mechanism 24 travels upwardly, which in turn causesa second end portion 52 of the lever 34 to move upwardly and the firstend portion 48 of the lever 34 to move downwardly. This movement iscoupled to the brake assembly 38 by connecting member 50, which pullsagainst the spring 46, thereby reducing tension in the brake band 40 andcausing a decrease in braking force so that the dispensing of tape canbe accelerated. Conversely, when tape tension is lowered, thetension-control mechanism 24 travels downwardly under the biasing forceof biasing member 28, which in turn allows the first end 48 of the lever34 to move upwardly. This motion permits the spring 46 to reapply moretensioning force to the brake band 40, thereby causing a correspondingincrease in the braking force to reduce the rate at which tape is beingdispensed.

When the first spool 16 becomes depleted of tape, splicing the trailingend of the tape from the first spool 16 to the leading end of the tapefrom the second spool 18 will automatically bring the second spool 18into action. The feedback mechanism serves to control the braking forcein response to tension spikes that can occur during and immediatelyfollowing splicing. For example, since the second spool 18 cannotimmediately supply tape at the rate required by downstream equipment(due to the inertia of the second spool 18), the tension in the tapesuddenly increases. The increased tension causes the tension-controlmechanism 24 to move upwardly, which in turn causes the brake assembly38 to reduce the braking force to allow rotation of the second spool 18.Also, the upward movement of the tension-control mechanism 24 shortensthe tape path, thereby providing tape to the downstream equipmentwithout requiring the second spool 18 to dispense a corresponding lengthcontemporaneously.

As the second spool 18 accelerates to the required speed, the tension inthe tape decreases, thereby allowing the tension-control mechanism 24 tobe pulled downwardly by the biasing member 28. This movement activatesthe brake band 40, which applies a gradually increasing braking force onthe second spindle 14 in response to the decrease in tape tension untilequilibrium is established.

As a spool is dispensing tape, the diameter of the tape on the spooldecreases. The feedback mechanism provided by the brake assembly 38,lever 34, tension-control mechanism 24, and biasing mechanism 28compensates for the diametrical change of the spool by graduallydecreasing the braking force to ensure substantially uniform tensionthroughout an entire roll. Without such a feedback system, the tensionin the tape would increase in proportion to the change in radius of thespool from which the tape is dispensed.

If, following a splicing operation, the second spool 18 acceleratesbeyond the rate at which tape is being pulled by the downstreamequipment, slack can form in the second spool 18. The slack can becomestuck to the spool, entangled with the tape path, and/or cause tapebreakage, which then requires a stoppage in production to fix theproblem. This phenomenon is known as “overrun.” Thus, to prevent such,overrun of the second spool following a splice, the brake band mustprovide a braking torque sufficient to prevent the second spool 18 fromaccelerating beyond the rate at which tape is being pulled by thedownstream equipment. It can be appreciated that increasing the rate atwhich tape is dispensed requires a corresponding increase in availablebraking torque to prevent over-acceleration of a spool following asplicing operation.

However, if the braking torque on a spindle is too high, the upwardpulling force of the tension-control mechanism 24 (caused by an increasein tension) may not be sufficient to overcome the spring 46 to permitthe spindle to accelerate to the required speed. Hence, the brakingtorque desirably should be great enough to prevent over-acceleration ata desired dispensing rate without adversely affecting the ability of thesystem to overcome the biasing mechanism (e.g., spring 46) that retardsrotation of the spindles.

In FIG. 1A, apparatus 10 is shown dispensing tape from the first spool16. When the tape from the first spool 16 is depleted, the trailing endportion of the tape from the first spool 16 can be spliced to theleading end portion of the tape from the second spool 18 to provide acontinuous feed of tape. While tape is being dispensed from the secondspool 18, another full spool of tape can be loaded onto the firstspindle 12. The leading end portion of the tape from the new spool canthen be spliced to the trailing end portion of tape from the secondspool 18. This process can be repeated as necessary with any number ofspools.

FIG. 1B shows an alternative embodiment of a dispensing apparatus thatcan be used to dispense tape. This embodiment shares many similaritieswith the embodiment of FIG. 1A. Hence, components in FIG. 1B that areidentical to corresponding components in FIG. 1A have the samerespective reference numerals and are not described further. Also, toprovide a more detailed disclosure without unduly lengthening thespecification, applicants incorporate herein by reference thedisclosures of co-pending U.S. application Ser. Nos. 10/359,521, filedFeb. 5, 2003 and 10/463,481, filed Jun. 16, 2003.

The apparatus shown in FIG. 1B includes a frame 1002 on which there aremultiple dispensers 1004 mounted on one side of the frame 1002 (one ofwhich is shown in FIG. 1B) and multiple dispensers 1004′ mounted on theopposite side of the frame 1002 (one of which is shown in FIG. 1B).Components of dispensers 1004′ that are identical to correspondingcomponents of dispensers 1004 are given the same respective referencenumerals, except that the reference numerals for the components ofdispensers 1004′ are followed by an apostrophe (′).

Instead of the brake band 40 (FIG. 1A), each spindle 12, 14 in theembodiment of FIG. 1B is provided with a brake assembly comprising arotor 1064 mounted to the inboard end of each spindle and a caliper 1066mounted at a fixed position relative to a respective rotor 1064. Eachcaliper 1066 is operable to provide a braking force to a respectiverotor 1064, such as by clamping or squeezing the rotor between twosurfaces of the caliper, as known in the art.

The dispenser 1004 includes an elongated tension member 1068, which isreeved around a pulley 1070 connected to end portion 48 of a lever 34and is coupled at its opposite end portions to calipers 1066 of thefirst and second spindles 12, 14. Tension member 1068 can be, forexample, a conventional brake cable, such as used in a brake assembly ofa bicycle. The calipers 1066 are normally biased to exert a quiescentbraking force to rotors 1064. Movement of tension member 1068 causes thecalipers 1066 to reduce the braking force applied to the rotors.

The dispenser 1004′ similarly includes a tension member 1068′ connectedat opposite ends to corresponding calipers of the upper and lowerspindles of the dispenser 1004′. In the illustrated embodiment, thebrake assemblies of the dispenser 1004′ are mounted in an “upside down”position to permit mounting in close proximity to the brake assembliesof the dispenser 1004. Because of this mounting arrangement, the endportions of the tension member 1068′ are reeved around pulleys 1090before being routed down to a pulley mounted on a respective lever (notshown) at the base of the dispenser 1004′.

The dispenser 1004 can also include a stop 1054 which limits upwardpivoting of end portion 52 of the lever 34 to protect the brake assemblyfrom excessive forces when there is an increase in tape tension.

Referring now to FIG. 2, a method for automatically splicing the tapefrom the second spool 18 to the tape from first spool 16 will now bedescribed. As used herein, the phrase “automatic splicing” or“automatically splicing” refers to splicing operations in which thetrailing end portion of a first spool is caused to splice to the leadingend portion of a second spool while substantially maintaining the rateat which tape is supplied to downstream equipment.

The tape from the first spool (also referred to as the “first tape”) 16has at its trailing end portion 60 a first splicing element 62. The tapefrom the second spool (also referred to as the “second tape”) 18 isprovided at its leading end portion 64 with a second splicing element66. When the first splicing element 62 engages the second splicingelement 66, the tapes become linked, causing the trailing end portion 60of the first tape 16 to pull the leading end portion 64 of the secondtape 18 into the downstream equipment.

Typically, the first tape spool 16 is provided with respective first andsecond splicing elements 62, 66 on its trailing and leading endportions, respectively, and the second tape spool 18 is provided withrespective first and second splicing elements 62, 66 on its trailing andleading end portions, respectively. In this way, any number of tapespools can be successively spliced together to provide a continuous feedof tape.

The first and second tapes can be any of various tapes known in the art(e.g., adhesive tapes, such as hot melt tapes, used in packaging). Forexample, the tapes can be those sold under the Sesame brand by AdalisCorporation, an H. B. Fuller Company, of Vancouver, Wash.

When the trailing end portion 60 of the first tape 16 comes off spindle12 (or the core of the tape roll supported on the spindle 12), it wouldnormally be free to twist or turn. In certain applications, suchmovement, however, may result in the tape being introduced into thedownstream equipment wrong side down. The second tape 18 would likewisebe misoriented. To avoid this problem, the trailing end portion 60 ofthe first tape 16 desirably is provided with a tail segment 68 affixedto the core (not shown) of the tape roll. The tail segment 68 has alength sufficient so that the second tape 18 becomes linked to the firsttape 16, in the proper orientation, before the end of the tail segmentis reached. In other applications, the tail segment 68 may not be neededor required.

In the illustrated embodiment, the tail segment 68 is detachablyconnected to the tailing end portion 60 of the first tape 16 with, forexample, a piece of tape 70 (e.g., masking tape). The other end of thetail segment 68 is securely affixed to the core of the tape roll. Whenthe first tape 16 draws the tail segment 68 tight, the masking tape 70is pulled free from the trailing end portion 60, leaving the tailsegment 68 dangling from the core and leaving the first and second tapes16, 18 free to travel into the downstream equipment.

In other embodiments, the tail segment 68 need not be detachable asshown. Instead, it can be securely affixed to the trailing end portion60 and not secured to the core. Thus, when the end of the tail segmentcomes free of the core, it is introduced into the downstream equipmentand applied with the first and second tapes 16, 18.

The first splicing element 62 can be attached to the trailing endportion 60 of the first tape in a variety of ways. FIG. 3 shows atechnique applicable to adhesive tapes, such as hot melt tapes. In thistechnique, the first splicing element 62 is placed on the tape and thetape is folded back and adhered to itself so as to secure the splicingelement between the two adjacent pieces of tape.

The first splicing element 62 in the illustrated configuration has agenerally flat, rectangular cross-sectional profile. In otherembodiments, however, the first splicing element 62 can have othershapes. For example, the first splicing element 62 can be elongated rodor pin shaped member. The first splicing element 62 has a length that isgreater than the opening in the second splicing element 66 to preventthe first splicing element 62 from passing through the opening, asfurther described below.

FIGS. 4-7 illustrate the second splicing element 66 in greater detail.As shown, the second splicing element 66 comprises a body including afirst flap or body portion 72 foldably coupled to a second flap or bodyportion 74 by a hinged portion 76. The body portions 72, 74 thereforecan be folded together to a closed position when placed around therunning first tape 16, as depicted in FIG. 7. In the illustratedembodiment, the splicing element 66 is made of a flexible, unitary pieceof material that can be folded widthwise in half at the hinged portion76. A score line (not shown) can be formed at the center of the splicingelement along the length of the hinged portion 76 to facilitate foldingthe body portions. The splicing element 66 can have a substantiallyuniform thickness along its length as shown. Alternatively, the hingedportion 76 can be formed from a center portion of reduced thicknessextending widthwise of the splicing element. In other embodiments, eachof the flap portions 72, 74 and the hinged portion 76 can be separatelyformed and subsequently joined to each other using suitable techniquesor mechanisms (e.g., fasteners or adhesives).

The splicing element 66 is made of a flexible, self-supporting material,which exhibits sufficient strength and rigidity to maintain a splice atthe desired dispensing speed. As used herein the term “self-supporting”refers to a material that can retain its shape under its own weight. Ifthe dispensing apparatus is dispensing tape into a corrugator (a devicefor making corrugated cardboard blanks) or similar devices, the firstand second splicing elements 62, 66 preferably are made of a materialthat can be applied to the cardboard blanks by the corrugator. Examplesof suitable materials for splicing elements 62, 66 include plastic,cardboard, paperboard, wood, composites, resin impregnated fiber (e.g.,carbon or glass fiber), metal, metal alloys, or combinations thereof.

The first and second body portions 72, 74 are formed with respectivefirst elongated slots, or openings, 78, 80 dimensioned to receive theleading end portion 64 of the second tape 18. The slots 78, 80 arepositioned such that they become aligned with each other when the bodyportions 72, 74 are folded closed. The leading end portion 64 of thesecond tape 18 can be secured to the second splicing element 66 byinserting the tape through the slots 78, 80 and folding back andadhering the tape to itself as shown in FIGS. 5-7. If non-adhesive tapeis used, then the tape can be inserted through the slots 78, 80 andsecured to itself using a suitable fastener.

The first and second body portions 72, 74 also are formed withrespective second elongated slots, or openings, 82, 84 spaced from theirrespective first slots 78, 80. The second slots 82, 84 are dimensionedto receive the first tape 16 and are positioned such that they becomealigned with each other when the body portions 72, 74 are folded closed.The first body portion 72 is formed with a slit 86 extending from aninner peripheral edge bounding the slot 82 to an outer peripheral edgeof the first body portion 72. A tab portion 90 partially bounds the slot82 and forms a bendable portion that can be bent or folded away from thefirst body portion to create a gap or opening between the opposing edgesof the slit 86. The second body portion 74 likewise is formed with aslit 88 extending from an inner peripheral edge bounding the slot 84 toan outer peripheral edge of the second body portion 74. A tab portion 92partially bounds the slot 84 and forms a bendable portion that can bebent or folded away from the second body portion to create a gap oropening between the opposing edges of the slit 88.

With the second splicing element 66 secured to the leading end portion64 of the second tape 18 (FIG. 5), the first body portion 72 is placedon the first tape 16 by bending tab portion 90 so as to create a gapbetween the opposing edges of the slit 86 and inserting the tape 16 intothe slot 82 via the gap (FIG. 6). Similarly, the second body portion 74is placed on the first tape 16 by bending tab portion 92 so as to createa gap between the opposing edges of the slit 88 and inserting the tape16 into the slot 84 via the gap (FIG. 7). The inner surface of thesecond body portion 74 (and/or the inner surface of the first bodyportion 72) can be provided with a piece of double-sided tape 94 (oranother suitable adhesive) (shown in FIGS. 4-6). Thus, when both thefirst and second body portions 72, 74 are placed around the first tape16, the body portions are pressed and held together in the closedposition (FIG. 7) by the tape 94.

In lieu of or in addition to the tape 94, other techniques or mechanismscan be used to retain the body portions 72, 74 in the closed position.For example, the first body portion 72 can have a locking member orlocking surface that forms a “snap fit” connection with a mating surfaceon the second body portion 74.

In the illustrated embodiment, the opposing edges of the slits 86, 88contact each other when the tab portions 90, 92 are in their normal,non-bent or closed positions shown in FIG. 4. In other embodiments,however, the first and second body portions can be formed with permanentgaps or openings between the opposing edges of the slits 86, 88 (i.e.,the opposing edges of the slits do not contact each other). The gaps canbe of sufficient width so as to permit the first tape 16 to be insertedinto the slots 82, 84 via the permanent gaps without bending the tabportions 90, 92.

In certain embodiments, the splicing element 66 can be made from aflexible, resilient material that has shape memory, such as plastic,such that the tab portions 90, 92 return to their original, closedpositions after the body portions 72, 74 are placed around the runningtape 16. In alternative embodiments, the splicing element 66 can be madeform a material that has little or no shape memory. In such embodiments,after the splicing element 66 is placed around the running tape 16, thetab portions 90, 92 are bent back to their original positions by anoperator.

The slots 82, 84 are dimensioned to permit the first tape 16 to freelypass through the second splicing element 66 while the first tape isbeing dispensed. The first splicing element 62 (FIGS. 2 and 3) has alength greater than that of the slots 82, 84. Thus, when the first spoolof tape 16 becomes depleted, the first splicing element 62 cannot passthrough the slots 82, 84, and therefore engages the second splicingelement 66, forming a splice between the trailing end portion 60 of thefirst tape 16 and the leading end portion 64 of the second tape 18.

When the first splicing element 62 engages the second splicing element66, the first splicing element exerts a pulling force on the secondsplicing element. As shown, the slits 86 and 88 desirably are formed onopposite sides of the splicing element 66. This configuration betterresists against flexure or deformation of the tab portions 90, 92 causedby the pulling force of the first splicing element 62 to retain thefirst tape 16 within the slots 82, 84 and maintain the splice. Theadhesive tape 94, by adhesively securing the tab portions 90, 92 againstopposing surfaces of body portions 74, 72, respectively (FIG. 7),further resists against flexure of the tab portions to maintain thesplice.

In particular embodiments, the splicing element 66 is made of plasticand has an overall thickness (when the body portions 72, 74 are foldedclosed) in the range of about 10 to 125 thousandths of an inch (about0.01 to 0.125 inch), and more desirably in the range of about 50 to 100thousandths of an inch (about 0.05 to 0.10 inch). Of course, thesespecific dimensions (as well as other dimensions provided in the presentspecification) are given to illustrate the invention and not to limitit. The dimensions provided herein can be modified as needed indifferent applications or situations.

FIGS. 8 and 9 show a splicing element 100, according to anotherembodiment, that can be used in lieu of splicing element 66 (FIGS. 4-7).The splicing element 100 includes a first body portion 102 and a secondbody portion 104 pivotally coupled to each other by a pivot pin 106extending through the body portions. The body portions 102, 104 can bepivoted relative to each other, in the directions indicated bydouble-headed arrow D, in mutually parallel planes between an openposition (FIG. 8) and a closed position (FIG. 9) in which the bodyportions overlap each other.

The first and second body portions 102, 104 are formed with respectivefirst elongated slots, or openings, 108, 110 dimensioned to receive theleading end portion of a standby tape (e.g., tape 18 in FIG. 2). Thefirst and second body portions 102, 104 also are formed with respectivesecond elongated slots, or openings, 112, 114 spaced from theirrespective first slots 108, 110. The second slots 112, 114 aredimensioned to receive a running tape (e.g., tape 16 in FIG. 2). Thefirst body portion 102 is formed with a slit 116 extending from an innerperipheral edge bounding the slot 112 to an outer peripheral edge of thefirst body portion 102. A tab portion 118 partially bounds the slot 112and forms a bendable portion that can be bent or folded away from thefirst body portion to create a gap or opening between the opposing edgesof the slit 116. The second body portion 104 likewise is formed with aslit 120 extending from an inner peripheral edge bounding the slot 114to an outer peripheral edge of the second body portion 104. A tabportion 122 partially bounds the slot 114 and forms a bendable portionthat can be bent or folded away from the second body portion to create agap or opening between the opposing edges of the slit 120. When the bodyportions 102, 104 are pivoted closed (FIG. 9), the first slot 108 of thefirst body portion 102 aligns with the first slot 110 of the second bodyportion 104, and the second slot 112 of the first body portion 102aligns with the second slot 114 of the second body portion 104.

The splicing element 100 is used in a manner similar to that describedabove in connection with the splicing element 66. For example, theleading end portion of a standby tape is secured to the splicing element100, such as by pivoting the body portions 102, 104 closed (FIG. 9) andforming a loop through the slots 108, 110 with the tape. The splicingelement 100 is then placed on a running tape, for example, by bendingtab portion 118 to create a gap, inserting the running tape into theslot 112 via the gap, bending tab portion 122 to create a gap, andinserting the running tape into the slot 114 via the gap. When thesplicing element on the trailing end portion of the running tape (e.g.,splicing element 62) engages splicing element 100, the standby tapebecomes spliced to the running tape.

FIG. 10 shows an alternative splicing apparatus comprising a firstsplicing element 200 secured to the trailing end portion 60 of the firsttape 16 and a second splicing element 202 secured to the leading endportion 64 of the second tape 18. In FIG. 10, the tapes are shown justprior to the first splicing element 200 engaging the second splicingelement 204 to form a splice. The first splicing element 200 can besecured to the trailing end portion 60 of the first tape in same manneras described for the splicing element 62 (FIGS. 2 and 3). For example,if adhesive tape is used, the first splicing element 200 is placed onthe tape and the tape is folded back and adhered to itself so as tosecure the splicing element between the two adjacent pieces of tape.

The first splicing element 200 in this embodiment has a generallyU-shaped configuration, rather than the rectangular shape of splicingelement 62 (FIGS. 2 and 3). Splicing element 200 has two leg portions220 spaced from each other a distance greater than the width of splicingelement 202 so that splicing element 202 can nest between the legportions when splicing element 200 engages splicing element 202.

Splicing element 202 is formed with an opening 204 dimensioned largeenough to permit passage of the first tape 16 but not splicing element200. The leading end portion 64 of the second tape 18 is secured to thesecond splicing element 202 by inserting the end of the tape through theopening 204 and folding back and adhering the tape to itself as shown. Agap 206 between leg portions 208, 210 extends from an inner peripheraledge bounding the opening 204 to an outer peripheral edge of thesplicing element 202. The gap 206 desirably is wide enough to allow thefirst tape 16 to be inserted through the gap 206 and into the opening.Instead of the illustrated gap 206, splicing element 202 can be formedwith a slit between leg portions 208, 210 with the adjacent surfaces ofthe leg portions contacting each other. A gap between leg portions 208,210 for inserting the first tape 16 into opening 204 can be created bybending or flexing one or both leg portions 208, 210, for example, bypulling the leg portions 208, 210 in opposite directions from eachother.

In another embodiment, splicing element 202 can be formed with aseparate slot or opening for securing the leading end portion 64 of thesecond tape 18.

In use, splicing element 202 (which is secured to the leading endportion 64 of the second tape 18) is placed around the first tape 16while it is being dispensed by inserting the first tape 16 into theopening 204 via the gap 206. When splicing element 200 engages thesecond splicing element 202, the first and second tapes become linked,causing the first tape to pull the second tape into the downstreamequipment. The second splicing element 202 should exhibit sufficientstrength and rigidity at the desired dispensing speed to resist againstdeformation of leg portions 208, 210 caused by the pulling force of thesplicing element 200 to maintain the splice. Because splicing element202 nests between leg portions 220 of splicing element 200, leg portions220 can engage the opposite sides of splicing element 202 and preventseparation of leg portions 208, 210 to assist in maintaining the splice.

FIGS. 11 and 12 show a splicing element 300, according to anotherembodiment, for securing to the leading end portion 64 of the secondtape 18. Splicing element 300 can be used in lieu of splicing element 66(FIGS. 4-7), splicing element 100 (FIGS. 8 and 9), or splicing element202 (FIG. 10). Splicing element 300 is formed from a wire defining agenerally closed geometric shape having an opening 302 for receiving thefirst tape 16 and two overlapping end portions 304 and 306. As usedherein, the term “wire” refers to a thin, elongated piece of material,and is not limited to metal wires. The length L of the opening 302 issized to allow the first tape 16 to freely pass through the opening, butrestrict passage of splicing element 62. In the illustrated embodiment,the splicing element 300 is generally rectangular. However, the splicingelement 300 may comprise any other geometric shape, such as a square,triangle, trapezoid, oval, circle, or various combinations thereof.Splicing element 300 can be made from any of various suitable materials,such plastic, metal, composites, or combinations thereof.

The leading end portion 64 of the second tape 18 is secured to thesplicing element 300 by inserting the end of the tape through theopening 302 and folding back and adhering the tape to itself as shown.To place splicing element 300 on a running tape (tape 16 in theillustrated embodiment), the end portions 304, 306 are separated fromeach other, such as by pulling or moving the end portions away fromeach, so as to form a gap between the end portions through which therunning tape can be inserted.

Splicing element 300 is made of a flexible material, but yet exhibitssufficient strength and rigidity to maintain a splice at the desireddispensing speed. In one implementation, splicing element 300 can bemade from a flexible, resilient material that has shape memory, such asplastic, such that the splicing element returns to its normal, closedshape (shown in FIGS. 11 and 12) after it is placed on a running tape.In alternative embodiments, splicing element 300 can be made from amaterial that has little or no shape memory. In such embodiments, afterthe splicing element is placed around a running tape, the end portions304, 306 are bent back to the overlapping, closed position (depicted inFIGS. 11 and 12) by an operator.

The splicing element 300 can be used in combination with splicingelement 62 as shown, or splicing element 200 (FIG. 10) for splicing astandby tape to a running tape.

FIGS. 13 and 14 illustrated another embodiment of a splicing systemcomprising a first splicing element 62 and a second splicing element400. Splicing element 400 is similar to splicing element 202 (FIG. 10),except that splicing element 400 is generally rectangular having curvedor rounded comers extending between the sides of the splicing element.Providing the splicing element with rounded comers can help the splicingelement avoid becoming caught on surrounding equipment or materials asthe tape is dispensed. Splicing element 400 is formed with an opening402 dimensioned large enough to permit passage of the first tape 16 butnot splicing element 62.

A gap 404 formed between end portions 406, 408 extends from an innerperipheral edge bounding the opening 402 to an outer peripheral edge ofthe splicing element 400. The gap 404 desirably is wide enough to allowthe first tape 16 to be inserted through the gap 404 and into theopening 402. The gap 404 desirably extends diagonally from the innerperipheral edge to the outer peripheral edge of the body as shown. Inthis manner, it is more difficult for the first tape 16 to pull throughthe gap 404 after a splice is formed.

In an alternative embodiment, an identical splicing element 400 can besecured to the trailing end portion 60 of the first tape 16, in lieu ofsplicing element 62. In this way, a manufacturer would only need tosupply one type of splicing element which can be used at the trailingand leading end portions of the tape rolls. Also, due to its enclosedshape, splicing element 400 is less likely to be inadvertently removedfrom the trailing end portion 60 of the first tape 16 than splicingelement 62.

In particular embodiments, splicing element 400 is made of plastic andhas an overall thickness in the range of about 10 to 125 thousandths ofan inch (about 0.01 to 0.125 inch), and more desirably in the range ofabout 50 to 100 thousandths of an inch (about 0.05 to 0.10 inch).

In view of the many possible embodiments to which the principles of thedisclosed invention may be applied, it should be recognized that theillustrated embodiments are only preferred examples of the invention andshould not be taken as limiting the scope of the invention. Rather, thescope of the invention is defined by the following claims. We thereforeclaim as our invention all that comes within the scope and spirit ofthese claims.

1. An apparatus comprising: a first, running spool of tape having atrailing end portion and a first splicing element secured to thetrailing end portion; a second, stand-by spool of tape having a leadingend portion and a second splicing element secured to the leading endportion; and wherein the second splicing element is made of aself-supporting material and has at least one aperture sized to receivethe tape from the first spool and a peripheral portion bounding at leasta portion of the aperture, whereby the tape being dispensed from thefirst spool can be introduced into the aperture by inserting the tapethrough a gap in the peripheral portion; wherein when the tape from thefirst spool is inserted in the aperture and the first spool becomesdepleted of tape, the first splicing element engages the second splicingelement so as to splice the tape from the first spool to the tape fromthe second spool.
 2. The apparatus of claim 1, wherein the firstsplicing element extends transversely across the tape of the first spooland has a length longer than the length of the aperture in the secondsplicing element.
 3. The apparatus of claim 1, wherein the secondsplicing element is a wire having a substantially closed geometricshape.
 4. The apparatus of claim 1, wherein the gap in the peripheralportion is a permanent gap extending from an inner peripheral edgebounding the aperture to an outer peripheral edge of the second splicingelement.
 5. The apparatus of claim 1, wherein the second splicingelement comprises at least one slit extending from an inner peripheraledge bounding the aperture to an outer peripheral edge of the secondsplicing element, whereby the gap in the peripheral portion is formedbetween the opposing edges of the slit by bending part of the peripheralportion.
 6. The apparatus of claim 1, wherein: the second splicingelement comprises a first body portion and a second body portionfoldably coupled to each other along a folding axis, allowing the firstand second body portions to be folded closed and opened relative to eachother; the at least one aperture comprises a first aperture in the firstbody portion and a second aperture in the second body portion; the firstbody portion comprises a first bendable tab portion bounding at least aportion of the first aperture which can be bent to create an opening inthe first body portion through which the tape from the first spool canbe inserted into the first aperture; the second body portion comprises asecond bendable tab portion bounding at least a portion of the secondaperture which can be bent to create an opening in the second bodyportion through which the tape from the first spool can be inserted intothe second aperture; and wherein when the tape from the first spool isinserted into the first and second apertures and the first and secondbody portions are folded closed, the first and second apertures alignwith each other to allow the tape from the first spool to pass throughthe second splicing element but not the first splicing element.
 7. Theapparatus of claim 6, wherein the second splicing element comprises anadhesive on one or both of the first and second body portions toadhesively secure the body portions to each other when the body portionsare folded closed.
 8. The apparatus of claim 6, wherein: the first bodyportion is formed with a first slit extending from an inner peripheraledge of the first aperture to an outer peripheral edge of the first bodyportion; and the second body portion is formed with a second slitextending from an inner peripheral edge of the second aperture to anouter peripheral edge of the second body portion.
 9. The apparatus ofclaim 8, wherein the first and second slits intersect the outerperipheral edges of the first and second body portions on opposite sidesof the second splicing element.
 10. The apparatus of claim 1, whereinthe second splicing element is made of a flexible, resilient material.11. The apparatus of claim 10, wherein the second splicing element ismade of plastic.
 12. The apparatus of claim 6, wherein: the first bodyportion comprises a third aperture; the second body portion comprises afourth aperture; and wherein the leading end portion of the second tapeforms a loop extending through the third and fourth apertures.
 13. Theapparatus of claim 1, wherein the leading end portion of the second tapecomprises a loop extending through another aperture in the secondsplicing element.
 14. The apparatus of claim 1, wherein: the secondsplicing element comprises a generally flat, first body portion and agenerally flat, second body portion pivotally coupled to each other at apivot axis, allowing the first and second body portions to be pivotedbetween closed and open positions relative to each other in mutuallyparallel planes; the at least one aperture comprises a first aperture inthe first body portion and a second aperture in the second body portion;the first body portion comprises a first bendable tab portion boundingat least a portion of the first aperture which can be bent to create anopening in the first body portion through which the tape from the firstspool can be inserted into the first aperture; the second body portioncomprises a second bendable tab portion bounding at least a portion ofthe second aperture which can be bent to create an opening in the secondbody portion through which the tape from the first spool can be insertedinto the second aperture; and wherein when the tape from the first spoolis inserted into the first and second apertures and the first and secondbody portions are pivoted to the closed position, the first and secondapertures align with each other to allow the tape from the first spoolto pass through the second splicing element but not the first splicingelement.
 15. A method of splicing a first, running tape to a second,stand-by tape, the method comprising: securing a first splicing elementto a trailing end portion of the first tape; securing a second splicingelement to a leading end portion of the second tape, the second splicingelement having at least one opening sized to receive the first tape, thesecond splicing element being made of a self-supporting material; andinserting the first tape into the opening of the second splicingelement, such that the first tape can pass through the opening and thefirst splicing element can engage the second splicing element to splicethe first tape to the second tape.
 16. The method of claim 15, whereininserting the first tape into the opening comprises forming a gap in aperipheral portion of the second splicing element bounding the opening,inserting the first tape into the opening via the gap, and closing thegap.
 17. The method of claim 15, wherein the first splicing elementcomprises a wire having two overlapping end portions.
 18. The method ofclaim 15, wherein: the second splicing element comprises a generallyflat body, a slit extending from the opening to an outer peripheral edgeof the body, and a bendable tab portion at least partially bounding theopening; and inserting the first tape into the opening comprises bendingthe tab portion so as to create a gap between the opposing edges of theslit, and inserting the first tape through the gap and into the opening.19. The method of claim 15, wherein: the second splicing elementcomprises a first body portion and a second body portion foldablycoupled to each other along a folding axis, allowing the first andsecond body portions to be folded closed and opened relative to eachother; the at least one opening comprises a first opening in the firstbody portion and a second opening in the second body portion; the firstbody portion has a first slit extending from the first opening to anouter peripheral edge of the first body portion; the second body portionhas a second slit extending from the second opening to an outerperipheral edge of the second body portion; and inserting the first tapeinto the opening comprises inserting the first tape through the firstslit and into the first opening, inserting the first tape through thesecond slit and into the second opening and folding the first and secondbody portions to a closed position.
 20. The method of claim 19, furthercomprising adhesively securing the first body portion to the second bodyportion.
 21. The method of claim 15, wherein securing the secondsplicing element to the leading end portion of the second tape comprisesinserting the leading end portion of the second tape through anotheropening in the second splicing element and folding back and adhering theleading end portion onto itself so as to form a loop.
 22. The method ofclaim 15, wherein the second splicing element is received between twospaced-apart leg portions of the first splicing element when the firstsplicing element engages the second splicing element.
 23. The method ofclaim 15, wherein the second tape is supplied from a stationary roll oftape that begins rotating from a stationary position after the firstsplicing element engages the second splicing element.
 24. The method ofclaim 15, further comprising dispensing the first tape from a first taperoll at a rate of at least 1,100 feet per minute and, after the firsttape is spliced to the second tape, dispensing the second tape from asecond tape roll at a rate of at least 1,100 feet per minute.
 25. Themethod of claim 15, further comprising dispensing the first tape from afirst tape roll at a rate of at least 1,400 feet per minute and, afterthe first tape is spliced to the second tape, dispensing the second tapefrom a second tape roll at a rate of at least 1,400 feet per minute. 26.A splicing element for use in splicing a first, running tape beingdispensed from a tape dispensing device to a second, standby tape, thesplicing element comprising a self-supporting body formed with at leastone aperture sized to receive the first tape, and a peripheral portionbounding at least a portion of the aperture, whereby the first tape canbe introduced into the aperture by inserting the first tape through anopening in the peripheral portion while the first tape is beingdispensed by the dispensing device.
 27. The splicing element of claim26, wherein the body is formed with at least one slot sized to receivethe second tape and spaced from the aperture.
 28. The splicing elementof claim 27, wherein: the body comprises a first body portion and asecond body portion foldably coupled to each other along a folding axis,allowing the first and second body portions to be folded closed andopened relative to each other; the at least one aperture comprises afirst aperture in the first body portion and a second aperture in thesecond body portion; the at least one slot comprises a first slot in thefirst body portion and a second slot in the second body portion, wherebya leading end portion of the second tape can be secured to the splicingelement by forming a loop of tape extending through the first and secondslots; whereby the first tape can be introduced into the first aperturevia an opening in the first body portion and into the second aperturevia an opening in the second body portion while the first tape is beingdispenses by the dispensing device.
 29. The splicing element of claim 28wherein: the first body portion comprises a bendable tab portion atleast partially bounding the first aperture and a slit extending fromthe first aperture to an outer peripheral edge of the first body portionsuch that the opening in the first body portion can be formed by bendingthe tab portion; and the second body portion comprises a bendable tabportion at least partially bounding the second aperture and a slitextending from the second aperture to an outer peripheral edge of thesecond body portion such that the opening in the second body portion canbe formed by bending the tab portion.
 30. The splicing element of claim28 further comprising an adhesive that adhesively secures the first andsecond body portions to each other when the body portions are foldedclosed.
 31. The splicing element of claim 26, wherein the opening in thebody is a permanent opening extending from the at least one aperture toan outer peripheral edge of the body.
 32. The splicing element of claim31, wherein the permanent opening extends diagonally from the at leastone aperture to the outer peripheral edge of the body.
 33. The splicingelement of claim 31, wherein the body is generally rectangular withrounded comers.
 34. A roll of tape comprising: a trailing end portion; aleading end portion; a first splicing element secured to the trailingend portion; and a second splicing element secured to the leading endportion, the second splicing element comprising a self-supporting bodyformed with at least one aperture sized to receive a running tapedispensed from another tape roll, and a peripheral portion bounding atleast a portion of the aperture, whereby the running tape can beintroduced into the aperture by inserting the running tape through anopening in the peripheral portion.
 35. The roll of tape according toclaim 34, wherein the first and second splicing elements have the sameshape.